Tool for working on a surface

ABSTRACT

An embodiment of a tool for working on a surface includes a tool support, a pad replaceably attached to a lower surface of the tool support, a working material replaceably attached to a lower surface of the pad, and a vacuum attachment member connected to the tool support.

RELATED APPLICATIONS

The present application is a continuation in part (CIP) to a U.S. patent application Ser. No. 11/271,374, filed on Nov. 10, 2005, which is a continuation of application Ser. No. 10/439,836, filed on May 16, 2003, now U.S. Pat. No. 6,991,529, the disclosures of which are incorporated in their entirety herein by reference.

INTRODUCTION

Hand held tool devices have been utilized in many fields for working the surface of a material, such as sanding, polishing, and painting, among others. For example, when fabricating a structure, such as a wall or ceiling in a building, oftentimes it is necessary to utilize a sanding device to smooth the surface of the structure. In response to this need, in the field of sanding devices, for example, various devices have been proposed.

One device utilizes a sanding head having an elongate rectangular shape. Such heads are designed to accommodate a standard sized elongate sheet of sand paper, thereby making the supply of sanding paper readily accessible. However, when the device is manipulated, due to its narrow configuration, the device tends to flip onto its elongate sides and can damage the surface of the wall, for example, by gouging the surface with the corners or edges of the device, requiring filling or additional sanding to remove the damage.

Another device utilizes a motorized rotating head that rotates rapidly to reduce the number of passes the device must take over an area. These devices are larger and more cumbersome due to the mechanical motor assembly and have a circular, non-continuous “O” shaped working surface due to the need to have access to a bolt. The bolt is seated in the center of the “O” defined by the working surface. This device takes a greater level of skill to master and if used improperly, can damage the surface by dishing to create swirl marks in the surface.

Further, devices have been proposed to vacuum away dust from the working surface, however, in devices proposed, the air is circulated around the working material (e.g., sand paper) and, therefore, only vacuums the dust that is at the edges of the device. Such devices have also typically been heavy and, therefore, difficult to maintain in position on the working surface, such as a wall or ceiling, among other surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a top perspective view of a tool having a vacuum attachment member according to an embodiment of the present disclosure.

FIG. 1B illustrates a cross sectional view of the tool embodiment shown in FIG. 1A.

FIG. 2A illustrates a side view of a tool according to an embodiment of the present disclosure.

FIG. 2B illustrates a side view of an embodiment of a tool pad structure.

FIG. 2C illustrates a side view of another embodiment of a tool pad structure.

FIG. 3 illustrates a bottom perspective view of a tool pad structure according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present invention provide working tools that provide suction to a working surface and/or dust removal from a working surface. One embodiment of a hand manipulated tool includes a tool support, a pad replaceably attached to a lower surface of the tool support, a working material replaceably attached to a lower surface of the pad, and a vacuum attachment member connected to the tool support.

FIG. 1A illustrates a top perspective view of a tool 100 having a vacuum attachment member 102 according to an embodiment of the present disclosure.

FIG. 1B illustrates a cross sectional view of the tool 100 shown in FIG. 1A including a pad 105. In the embodiment illustrated in FIGS. 1A and 1B, the tool 100 includes a boot 103, a base 104, a pivot shaft 120, and a tool support 101 having a periphery 109.

In various embodiments, the vacuum attachment member (e.g., 102) includes an outlet (e.g., 126 shown in FIG. 1B) for releasable attachment to a vacuum source (e.g., a shop vacuum or other vacuum source not shown). As described herein, in various embodiments, a vacuum source can be connected to the vacuum attachment member and operated to provide suction of a working surface to a wall and/or to remove dust from a working surface via one or more apertures and/or channels in the tool support (e.g., tool support 101).

As shown in FIG. 1B, the vacuum attachment member 102 includes an outlet 126 for releasable attachment to a vacuum source (not shown) in any suitable manner. For example, the outlet 126 can be threaded and/or tapered in various embodiments for receiving a hollow end of a hollow pole or hose (not shown) which can in turn be connected to a vacuum source (e.g., a portable type vacuum or other vacuum source).

In the embodiment illustrated in FIGS. 1A and 1B, the vacuum attachment member 102 is a pivoting structure attached to a base portion 104 of the tool support 101. The tool support can be a rigid tool support made of various metals and/or rigid plastics, among various other rigid materials.

The shape of the tool support and/or one or more of the other layers of the tool can have any suitable shape. For example, in various embodiments of the present disclosure, the periphery of the tool support has at least five points that are equidistant from the center 113. As shown in FIG. 1A, the support 101 has a periphery 109 defined by its outside edge and the periphery 109 has many points that are equidistant from the center 113 of the support 101.

In some embodiments, one or more of the various layers of the tool can have a circular, oval, polygonal, or irregular shape. The tool support 101 can, for instance, have a triangular, square, rectangular, pentagonal, hexagonal, or octagonal shape, among various other shapes.

In various embodiments, at least five points on the periphery 109 are equidistant from the center 113 of tool support 101. Such shapes may allow the tool to be more resistant to tipping. In some embodiments, the tool support can have at least four intersecting edges equidistant from a center of the support.

In the embodiment of FIGS. 1A and 1B, the tool 100 includes a rigid tool support 101 that can be attached to the vacuum attachment member 102 in any suitable manner, as discussed above. For example, as shown in FIG. 1B, the tool support 101 can be attached to the attachment member 102 by a pivoting structure.

In the example shown in FIG. 1B, two pivoting structures are provided with a first piece 121 having a pivoting point 120 that is connected to an end of member 102, also having a pivot point 123. In such embodiments, the first piece 121 allows the attachment member 102 to pivot radially with respect to the attachment point of the attachment member 102 to the tool support 101.

The connection of the end of attachment member 102 via its pivot point 123 can allow the support 101 to pivot radially with respect to the attachment point of the attachment member 102 to the tool support 101, but generally perpendicular to the pivotal movement provided by the first piece 121. The use of the two pivot points can allow for the vacuum attachment member 102 to achieve many positions with respect to the tool support 101.

However, embodiments of the present disclosure are not limited to the use of the two directional pivotable attachment structure shown. For example, a ball joint or other universal joint type structure can be utilized. Further, in some embodiments, the attachment member 102 can be fixed with respect to the tool support 101.

In various embodiments, the tool can include various numbers of layers and one or more of the layers may include one or more apertures and/or channels therethrough. The one or more apertures and/or channels that can be provided in the tool support and/or any of the various layers herein can be of any suitable shape.

In the embodiment illustrated in FIG. 1B, the tool support 101 includes a number of apertures 125 through tool support 101. In various embodiments, the apertures 125 can be in fluid communication with an outlet 126 formed in the vacuum attachment member 102.

In the embodiment of FIGS. 1A and 1B, the tool 100 includes a vacuum chamber defined by the interior of a base 104 and the interior of a boot 103. The base 104 is designed to be in fluid (e.g., air) communication with apertures 125 such that fluid can pass between the interior of the base 104 and the apertures 125.

The boot can be flexible or rigid, and/or can be constructed from a variety of materials including synthetic or natural elastomeric materials, metals, and/or plastics. In some embodiments, and as shown in the embodiment of FIG. 1B, the boot 103 can be formed around one or more openings in the base 104, such as the central opening illustrated in the embodiment of FIG. 1B. The interior of the boot 103 can be in fluid communication with the outlet 126 and the base 104 and/or apertures 125 to provide suction to remove dust from a working surface when the outlet 126 is attached to a vacuum source.

In the embodiment shown in FIG. 1B, the tool support 101 includes a pad 105 attached to the lower surface of the support 101. The pad can be a rigid, i.e. inflexible, or resilient material and, in some embodiments, the pad can be releasably attached to the tool support.

In an embodiment, where the pad is a resilient material, it can be utilized, for example, to cushion the force of the support on the surface being worked on, among other benefits. In an embodiment where the pad is an inflexible material, it can be utilized, for example, to distribute force more directly to the surface being worked on, among other benefits.

As described herein, in various embodiments, the pad can be fluid permeable to allow the passage of dust therethrough. Also, in various embodiments, one or more apertures can be provided in the pad. In some embodiments, the apertures in the pad can be aligned with the apertures in the tool support.

A working material can also be positioned on the tool support itself and in some embodiments, the working material can be releasably attached to the tool support. Such embodiments allow for the working material to be removed and replaced and/or changed to a different kind of working material.

In some embodiments, the pad can have a working material attached thereto (e.g., to a bottom surface and/or one or more side surfaces of the pad). In various embodiments, the working material can be releasably attached to the pad. In such embodiments, the working material can then be replaced without changing the pad and the pad can be replaced without having to dispose of the working material.

Working materials can be any type of material that can be utilized to perform work on a surface. Some examples of working materials include, but are not limited to abrasive materials such as sand paper, materials for the application of paint or stain, and materials for polishing, among others. In various embodiments, the working material is an fluid permeable material.

In such embodiments, the fluid permeability allows for the vacuum force to pass through the working material to the working surface. Such force can, in some embodiments, vacuum dust that is under the working material. The force can also, in some embodiments, provide a suction force to the working surface. Such a force can aid in maintaining the tool in position on the working surface.

In some embodiments, the flow of fluid to the tool (e.g., 100) can be reversed such that the air blows onto the working surface rather than being sucked off of the surface. In such embodiments, the vacuum source is actually an fluid source. Many vacuum devices provide the ability to switch the direction of fluid flow in such a manner. As used herein, the term “vacuum source” should be construed to include devices that can blow fluid onto the working surface.

FIG. 2A illustrates a side view of a tool 200 according to an embodiment of the present disclosure. FIG. 2A illustrates a tool embodiment 200 having a base 204 positioned over apertures 225. The base 204 receives an end of vacuum attachment member 202 through an opening therein and also includes a boot 203. In the embodiment of FIG. 2A, tool support 201 has an attachment layer 206 connected thereto.

In various embodiments, the attachment layer can be, for example, hook and loop fasteners that can be utilized to releasably attach one or more layers of the tool to one another. For instance, attachment layer 206 can be used to releasably attach a lower surface of tool support 201 to a pad 205. The attachment layer can include a number of fastening mechanisms including but not limited to, glues, epoxies, and other mechanical attachment structures, to name a few.

In the embodiment illustrated in FIG. 2A, the apertures 225 are shown as being aligned from tool support 201 down through attachment layer 206 and pad 205. In some embodiments, the apertures may extend partially through pad 205. In various embodiments the pad 205 can have a number of apertures and/or channels therethough.

In various embodiments of the present disclosure, the pad layer 205 can be a working material. The working material can be any material suitable for conditioning a surface. Such materials include, but are not limited to abrasives, polishers, and liquid applicators for the application of paints, stains, and the like.

In some embodiments, the working material can include a rigid backing having a number of hard particles provided thereon. In embodiments in which the working material includes a rigid backing, the rigid backing can be formed of various metals such as stainless steel, among other rigid materials.

The hard particles on the rigid backing can be particles of various materials. In embodiments in which the working material includes a rigid backing having a number of hard particles provided thereon, the number of particles can be ultra hard particles. As used herein, ultra hard particles refers to particles of materials having a hardness of at least 7 on a Mohs hardness scale in which diamond has a hardness of 10. Examples of ultra hard materials include tungsten carbide, silicon carbide, boron carbide, aluminum oxide, and steel, among others.

In various embodiments, the rigid backing can reduce or prevent the ultra hard particles from damaging the rigid backing by penetrating the backing while the tool is applied to a working surface, as can occur with working materials having non-rigid backings (e.g., sandpaper or other abrasives having non-rigid backings). In such embodiments, the rigid backing can be replaceably attached to the tool support such as via releasable fastening structures including mechanical and/or chemical structures. Suitable mechanical structures include hook and loop attachments among others. Suitable chemical structures include releasable glues, adhesives, epoxies, and the like. One suitable adhesive is a pressure sensitive adhesive (PSA).

In embodiments in which the working material includes a rigid backing, the particles can be provided thereon in various manners. For example, the particles can be brazed on the rigid backing, and/or can be adhered to the rigid backing via an epoxy and/or other adhesive suitable for permanently adhering the particles to the rigid backing.

In various embodiments, the working material can include a grit size of less than or equal to an ISO (international organization for standardization) 6344 standard size of P24. That is, in such embodiments the coarseness of the grit is P24 or coarser. In such embodiments, the coarseness and/or hardness of the working material can be beneficial in applications such as scoring EPS (Expanded Polystyrene) foam or removing some ceiling textures, among other applications.

In embodiments in which the working material includes a rigid backing, the rigid backing can have various shapes as described herein. For instance, in some embodiments, the rigid backing can have a periphery having at least five points equidistant from a center of the tool support. In some embodiments the shape of the rigid backing can be the same as the shape of the tool support and/or a pad attached thereto.

In embodiments in which the working material includes a rigid backing, the rigid backing can have a number of apertures and/or channels therethrough. In embodiments in which the rigid backing has a number of apertures and/or channels therethrough, the apertures and/or channels can have various shapes. For instance, the channels may be curved channels having a cresecent shape or other curved shape.

In embodiments in which the rigid backing has a number of apertures and/or channels therethrough, the channels can facilitate suction to and/or dust removal from a working surface (e.g., a wall, floor, ceiling, table top, etc.).

FIG. 2B illustrates a side view of an embodiment of a tool pad structure. In the embodiment of FIG. 2B, the tool support 201 has a working material 207 attached to it by an attachment layer 206. In such embodiments, the tool with working material provide a low profile that and can aid in distributing force more directly to the material 207.

In the embodiment of FIG. 2B, the working material 207 is shown as an abrasive material, such as sand paper. As stated above, the working material can be any material suitable for conditioning a surface. Such materials include, but are not limited to abrasives, polishers, and liquid applicators for the application of paints, stains, and the like.

In the embodiment shown in FIG. 2B, apertures 225 are provided in the tool support 201, but are not provided in the attachment layer 206 or the working material 207. In such embodiments, the attachment layer 206 and/or the working material can be fluid permeable. For example, in various embodiments, the working material can be an fluid permeable sanding material (e.g., sand paper) such that adequate suction to a working surface and/or adequate sanding dust removal can be obtained in the absence of apertures through layers 206 and/or 207. Such embodiments may provide easier and/or less costly manufacturing and may provide a different vacuum force and/or duct collection ability based upon the passing of the fluid through the one or more materials instead of through apertures formed therein.

Alternatively, in some embodiments, neither the attachment layer 206 nor the working material 207 is fluid permeable. In such embodiments, apertures may be provided in either or both of layers 206 and 207. In some embodiments with an fluid impermeable layer 207, apertures can be provided out to the edge of layer 206 through the layer 206. In some embodiments, such as that illustrated in FIG. 2C, the apertures can be formed generally perpendicular to the attachment surfaces of the layers.

FIG. 2C illustrates a side view of another embodiment of a tool pad structure. The embodiment illustrated in FIG. 2C includes a tool support 201, a pad 205, an attachment layer 206 that attaches the support 201 to the pad 205, a working material 207, and an attachment layer 208 that attaches the working material 207 to the pad 205. In the embodiment of FIG. 2C, the pad 205 can be utilized, for example, to cushion the force of the support 201 on the working material 207. In various embodiments, the pad can have a working material formed thereon and, therefore, there would be no need for an attachment layer (e.g., layer 208) to be utilized between the pad and the working material.

The embodiment of FIG. 2C illustrates the use of an attachment layer 206, such as for example hook and loop fasteners, that can be utilized to releasably attach the working material 207 to the support 201. The embodiment of FIG. 2C also illustrates the use of a working material 207 attached to the lower surface of the pad 205 by an attachment layer 208. Any suitable fastening mechanism can be utilized for the attachment of any of the layers, such as support 201, pad 205, attachment layers 206 and 208, working material 207, and the like, to one another.

In the embodiment of FIG. 2C, tool support 201 and layers 205, 206, and 208, each have apertures 225 formed therethrough. In the embodiment of FIG. 2C, working material 207 is an fluid permeable sanding material. As mentioned above, some or all of layers 205, 206, 207, and 208 can be fluid permeable. In various embodiments, it can be beneficial to provide apertures that are aligned through layers which are not fluid permeable in order to facilitate suction to and/or dust removal from a working surface (e.g., a wall, floor, ceiling, table top, etc.).

In embodiments that utilize one or more releasable fastening mechanisms an individual can rapidly replace or change the types of working materials that can be utilized. In some embodiments, an individual can replace or change and/or can add pads to the tool without having to remove a connected vacuum source from the vacuum coupling.

FIG. 3 illustrates a bottom perspective view of a tool pad structure 300 according to an embodiment of the present disclosure. The embodiment shown in FIG. 3 can include a vacuum attachment member attached to an upper surface of tool support 301 as discussed above in connection with FIGS. 1A and 1B.

In the embodiment illustrated in FIG. 3, the lower surface of tool support 301 has a pad 305 attached with an attachment layer 306. In the embodiment of FIG. 3, the pad 305 includes an attachment layer 308.

The embodiment illustrated in FIG. 3 illustrates two circular apertures 325 which are spaced a distance from the center 313 of support 301. In various embodiments, apertures can be provided through one or more of the tool support 301 and layers 305, 306, and 308.

Also, in this embodiment, attachment layer 308 includes a number of apertures 330 therein. In some embodiments, the apertures 330 can be formed in the pad 305. As shown in the embodiment illustrated in FIG. 3, the apertures 330 are not formed in the pad 305 (e.g., the pad 305 is exposed at the location of the apertures 330 in the attachment layer 308.

In some embodiments, the apertures 330 can be slits of various sizes and/or shapes that can be used to facilitate dust removal by drawing dust in from areas other than immediately proximate to the apertures 325. In such embodiments, the slits can also be used to provide exposure to the pad 305 beneath layer 308. In such embodiments, the pad 305 can be fluid permeable.

In various embodiments, a working material (e.g., an air permeable sanding material) can be attached to engagement surface 308 when tool 300 is to be operated by an individual. In such embodiments, when tool 300 is attached to an operating vacuum source (e.g., a shop type vacuum) the negative pressure created can suck fluid and dust through apertures 325 as well as thorough apertures 330 due to the fluid permeability of pad 305.

Embodiments of the present disclosure are not limited to the embodiment illustrated in FIG. 3. For example, in various embodiments, the tool can include more or less than two apertures 325 and/or more or less apertures 330 than are illustrated in the embodiment of FIG. 3.

Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve the same techniques can be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention.

It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combination of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description.

The scope of the various embodiments of the disclosure includes any other applications in which the above structures and methods are used. Therefore, the scope of various embodiments of the disclosure should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.

In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the embodiments of the invention require more features than are expressly recited in each claim.

Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. 

1. A tool for working on a surface, comprising: a tool support; a pad replaceably attached to a lower surface of the tool support; a working material replaceably attached to a lower surface of the pad; and a vacuum attachment member connected to the tool support.
 2. The tool of claim 1, where the vacuum attachment member includes an outlet for releasable attachment to a vacuum source.
 3. The tool of claim 1, where the vacuum attachment member is pivotally connected to the tool support.
 4. The tool of claim 1, where the pad includes a plurality of apertures therethrough, the apertures in fluid communication with an aperture through the tool support.
 5. The tool of claim 1, where the pad is replaceably attached to the lower surface of the tool support via a hook and loop fastening structure.
 6. The tool of claim 1, where the tool support is a rigid tool support.
 7. The tool of claim 1, where the tool support has a periphery with at least five points equidistant from a center of the tool support.
 8. A tool for working on a surface, comprising: a tool support; a pad replaceably attached to a lower surface of the tool support; a working material replaceably attached to a lower surface of the pad via a hook and loop fastening structure; and a vacuum attachment member connected to the tool support, the vacuum attachment member including an outlet for releasable attachment to a vacuum source.
 9. The tool of claim 8, where the pad is replaceably attached to the lower surface of the tool support via a hook and loop fastening structure.
 10. The tool of claim 8, wherein the tool support is pivotally connected to the vacuum attachment member.
 11. The tool of claim 10, wherein the vacuum attachment member is releasably attachable to an elongate hollow handle.
 12. The tool of claim 8, where the tool support includes a periphery having a circular shape.
 13. The tool of claim 12, where the pad includes a periphery having a circular shape.
 14. The tool of claim 13, where the working material includes a periphery having a circular shape.
 15. A tool for working on a surface, comprising: a tool support; a pad replaceably attached to a lower surface of the tool support; a working material attached to a lower surface of the pad, the working material including a rigid backing; and a vacuum attachment member connected to the tool support, the vacuum attachment member including an outlet for releasable attachment to a vacuum source.
 16. The tool of claim 15, where the working material is replaceably attached to the lower surface of the pad.
 17. The tool of claim 15, where the working material is replaceably attached to the lower surface of the pad via a hook and loop fastening structure.
 18. The tool of claim 15, where the pad is replaceably attached to the lower surface of the tool support via a hook and loop fastening structure.
 19. The tool of claim 15, where the rigid backing includes a number of hard particles formed thereon.
 20. The tool of claim 15, where the rigid backing includes a number of apertures therethrough. 